Compact medication reconstitution device and method

ABSTRACT

A container usable for lyophilization, storage, and reconstitution of medication having only two parts, one of which is a plug component having a flow path terminating in a side outlet port and a second of which is a barrel component. The barrel component has a spiral mixing channel near its distal end in which powder medication is stored and upon reconstitution, yields a gradient concentration. The inner wall of the barrel includes a longitudinal diluent groove. To connect the plug outlet port with the longitudinal diluent groove, the plug or barrel has a 360° distribution groove encircling the plug and connecting to the plug outlet port. Regardless of what rotational orientation the plug has to the barrel, the diluent will always reach the mixing channel.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.61/431,319, filed Jan. 10, 2011, and this application is acontinuation-in-part of application Ser. No. 13/159,346, filed Jun. 13,2011, which is a division of application Ser. No. 11/716,223 filed Mar.9, 2007, which is now U.S. Pat. No. 7,959,600, which is acontinuation-in-part of application Ser. No. 11/172,064 filed Jun. 30,2005, which claims the benefit of 60/640,625 filed Dec. 30, 2004, all ofwhich are incorporated herein by reference.

BACKGROUND

The invention relates generally to medication reconstitution and moreparticularly, to a compact device and method for storing and rapidlyreconstituting dried medications.

Due to continued advances in genetic and cell engineering technologies,proteins known to exhibit various pharmacological actions in vivo arecapable of production in large amounts for pharmaceutical applications.However, one of the most challenging tasks in the development of proteinpharmaceuticals is to deal with the inherent physical and chemicalinstabilities of such proteins, especially in aqueous dosage forms.Pre-filled hypodermic syringes in which these protein pharmaceuticalsand other medications are stored in aqueous form offer manyefficiencies. However, many injectable medications degrade rapidly andlose their effectiveness in solution. Refrigeration and specialpackaging can increase shelf life, but add to cost, complicate storage,and offset many efficiencies provided by pre-filled syringes.

Because of the instability associated with the aqueous dosage forms,powder formulations are generally preferred to achieve sufficientstability for the desired shelf-life of a product. Various techniques toprepare dry powders are known and practiced in the pharmaceutical andbiotechnology industry. Such techniques include lyophilization,spray-drying, spray-freeze drying, bulk crystallization, vacuum drying,and foam drying. Lyophilization (freeze-drying) is often a preferredmethod used to prepare dry powders (lyophilizates) containing proteins.Various methods of lyophilization are well known to those skilled in theart. The lyophilization apparatus and process applies a vacuum thatconverts liquid portions of a medication into a solid which is subjectto a sub-atmospheric pressure to create a vapor. The vapor is drawn fromthe lyophilization chamber through vapor passages and exhausted toregions external of the lyophilizing apparatus. The lyophilizing processreduces the liquid medication to a dried powdery or granular form.

More particularly, freeze drying, or lyophilization, is a dehydrationtechnique. It takes place while a product is in a frozen state (icesublimation under a vacuum) and under a vacuum (drying by gentleheating). These conditions stabilize the product, and minimize oxidationand other degradative processes. The conditions of freeze drying permitrunning the process at low temperatures, therefore, thermally labileproducts can be preserved. Freeze drying has become an accepted methodof processing heat sensitive products that require long term storage attemperatures above freezing.

Steps in freeze drying include pretreatment, freezing, primary dryingand secondary drying. Pretreatment includes any method of treating theproduct prior to freezing. This may include concentrating the product,formulation revision (i.e., addition of components to increase stabilityand/or improve processing), decreasing a high vapor pressure solvent orincreasing the surface area. Methods of pretreatment include: freezeconcentration, solution phase concentration, and formulatingspecifically to preserve product appearance or to provide lyoprotectionfor reactive products.

The second step is to freeze the product. Freezing the product decreaseschemical activity by decreasing molecular movement. Freezing isessentially the dehydration step in freeze drying; once the solventmatrix is in the solid (frozen) state, the solute matrix is “dry,”(although it may contain some amorphous water). A rule of thumb forfreezing product is that the product container should preferably not befilled with product to more than half of its total volumetric rating. Inpractice this may also mean filling the product only to certain depth tofacilitate freezing, ice sublimation and final water/solvent removal.This helps insure, in most cases, that the surface to depth ratio issuch that freeze drying is not impeded by the product depth.

Once the product is at the end of its lyophilization cycle it should beremoved from the freeze dryer. In a stoppering shelf/tray dryer, aninert gas may be bled into the chamber forming an inert “gas cap” overthe product prior to stop. Many products are simply stoppered whileunder vacuum. The stoppers used most commonly on serum vials/bottleshave a vacuum integrity of approximately five years when used inconjunction with tear off seals. Once the product is stoppered, thesystem is returned to atmospheric pressure and the lyophilizing shelvesare unloaded.

Many devices presently exist in which lyophilized medication is storedin the chamber of a hypodermic syringe. Shortly prior to delivery to apatient, reconstitution is achieved by removing the tip cap from thesyringe and placing the sharpened cannula of the syringe into a diluentcontainer such as a vial, ampule, or any other rigid or flexiblereservoir which could be engaged to the syringe. The plunger of thesyringe is then pulled proximally to draw the diluent into thelyophilized medication chamber for mixing. The diluent reservoir is thenremoved and discarded. The diluent/powder solution in the syringe isthen shaken sufficiently for complete mixing. Unless a sharpened cannulais already attached, one is mounted to the distal end of the syringe andthe cannula is used to pierce the patient's skin at an injection site.The syringe plunger is then pushed into the syringe barrel to deliverthe mixture to the patient. If necessary, the needle used forreconstitution of the lyophilized medication can be removed and replacedwith a cannula more suitable for injection into a patient. An example ofa system of this nature is that shown in U.S. Pat. No. 5,752,940 toGrimard.

More complex prior art includes hypodermic syringes made of glass orplastic having multiple chambers; in most cases two chambers. In oneparticular case, a chamber has a stopper slidably disposed at anintermediate position. A lyophilized medication is stored in the chamberdistally located to the stopper, while a selected diluent is stored inthe chamber proximally of the stopper. A plunger is slidably disposed influid-tight engagement with the chamber wall proximally of the diluent.Movement of the plunger in a distal direction urges both the diluent andthe stopper toward the lyophilized medication. The stopper eventuallywill align with a bypass region formed in the syringe barrel, andfurther movement of the plunger will cause the diluent to flow throughthe bypass and into the distal portion of the chamber for fully mixingwith the lyophilized medication. An example of a hypodermic syringesimilar to the above is shown in U.S. Pat. No. 4,599,082 to Grimard.

The two-component hypodermic syringe assembly described above canfunction well; however, the need for two axially-spaced chambers alongthe body of the hypodermic syringe necessitates a longer syringe. Inparticular, the need for a chamber large enough to mix all of thediluent with all of the lyophilized medication before delivery to thepatient dictates a space requirement that makes a container larger thanif all the diluent and medication were not mixed before the deliverystep. Since the lyophilizing process generally is carried out in thesyringe, the lyophilizing apparatus must then be large enough toaccommodate the longer syringe. Larger hypodermic syringes andcorrespondingly larger lyophilizing apparatus are more costly andrequire more space, which also increases cost.

Currently known devices and methods require thorough reconstitution andmixing of a lyophilized product into a diluent prior to injection, andcan typically involve lengthy procedures (in excess of ten steps) inorder to reconstitute a solid medication into a liquid formulation priorto administration. Such lengthy reconstitution steps can be complex,arduous, and tedious and may render injection of the lyophilized productunfeasible. Moreover, these complicated procedures present risks offoaming, contamination, and accidental needle pricks to the caregiver.

One of the most important aspects with the distribution of lyophilizedproduct is the reliability of the container. Another important aspect isthe control over costs of distribution. Devices used for pharmaceuticalproducts must be disposable but at the same time, of high quality sothat the patient is assured of accurately receiving the medicationprescribed. Containers for lyophilized medical products should have alow cost, should be reliably usable, and should not negatively affectthe shelf life of the product or its quality. Additionally the containershould be easily and safely usable and intuitive to use. Containershaving a large number of parts can be less reliable and more expensiveto manufacture. Those with movable parts are more so.

By using a diluent from a separate vial or ampule, a separate space fora diluent is not required in the medication container, and it can bemore compact. Thus, the syringe barrel can be substantially shorter thanprior art two-component syringe assemblies, and a smaller lyophilizingapparatus also can be used. Even better is the use of blunt cannulas toconduct the diluent into the lyophilized medication. Providing areconstitution container that does not include a movable plunger is evenbetter for reliability and reduced cost.

In prior reconstitution devices and methods, the diluent is fully mixedwith the lyophilized medication before delivery to the patient. In suchfully mixed form, the concentration of the medication in the patientdelivery is constant throughout the entire injection as is shown in FIG.1 by line 30; i.e., there is no gradient. However, it has been found insome therapeutic settings that a gradient delivery of medication wouldbe clinically beneficial to a patient. In particular, a higherconcentration of the medication in the initial delivery tapering to alower concentration during later delivery, as is shown in FIG. 2 by line36, has been found to provide certain advantages. A device and methodthat provide such a concentration gradient delivery profile without anyseparate manipulation would be beneficial.

Hence those skilled in the art have recognized the need for an improvedreconstitution device that facilitates lyophilization, storage, and therapid reconstitution of dried medications. Another need has beenrecognized for a reduced size reconstitution device so that costs bothin lyophilization and storage are reduced. Another recognized need isfor the ability to reduce the number of steps in reconstitution of adried medication. Reduction in manufacturing complexity and cost arealso needs recognized by those of skill in the art. An additional needhas been recognized for a device that controllably delivers with agradient concentration. The present invention fulfills these needs andothers.

BRIEF SUMMARY OF THE INVENTION

Briefly and in general terms there is provided a compact medicationlyophilization and reconstitution container arranged so that diluentreconstitutes dried medication rapidly upon contact in a concentrationgradient.

In accordance with aspects of the invention, there is provided areconstitution container device for reconstituting a dried medication,the reconstitution container device comprising a plug component having aproximal end, a distal end, and a side portion disposed between theends, the side portion having a periphery with an outer surface, theplug component having an external diluent connector port, and having aninternal diluent flow path from the diluent connector port to a plugoutlet port located at the side periphery, a barrel component engagedwith the plug component, the barrel component having a wall with aninner surface within which is formed an internal cavity with a sizeselected to contain a predetermined quantity of liquid medication fordrying to a powder, the barrel component also having a distal end withan external ejection connector port, an elongated channel wall having awinding shape in which it winds around itself to form an elongatedwinding mixing channel, the channel wall being located within the barrelcomponent such that the channel has a closed bottom and an open top, thechannel wall having a height and length selected to contain the entirequantity of powder completely within the mixing channel while stillhaving open space remaining in the mixing channel, the mixing channelhaving an input end and an output end with the output end connected withthe ejection port, a continuous diluent distribution groove completelyencircling the plug side portion and formed in at least one of the plugside portion and the inner surface of the barrel, the diluentdistribution groove located so as to be connected with the plug outletport, a diluent interconnecting groove formed longitudinally in thesurface of the inner wall of the barrel component having a lengthselected to connect with the diluent distribution groove and with theinput end of the mixing channel, wherein the mixing channel provides anindirect flow path between the diluent interconnecting channel and theejection port, wherein the top of the elongated channel wall is locatedwithin the barrel component facing the plug component so that when theplug component and the barrel component are assembled together after theliquid medication is dried, the distal end of the plug component pushespowder into the mixing channel, and contacts and closes the top of theelongated mixing channel so that the only access to the powder isprovided by the input and output ends of the mixing channel, and whereinforcing diluent through the diluent port causes it to flow through theplug component, through the distribution groove, through the diluentinterconnecting groove, into the input end of the mixing channel, andthrough the space in the mixing channel in contact with the powder,reconstituting the powder to form a delivery solution having amedication concentration gradient as it flows out the ejection port withinitial flow of reconstituted solution having a higher concentration ofthe medication than later flow of reconstituted medication.

In more detailed aspects, the elongated winding channel wall isintegrally formed as part of the barrel component such that the barrelcomponent and the winding mixing channel are a single piece, and whereinthe plug component comprises a distal closure surface that, whenassembled with the barrel component, forms the closing top of thewinding mixing channel. The elongated channel wall is wound arounditself to form a mixing channel having a spiral shape. The plugcomponent having the proximal end, distal end, side portion, externaldiluent connector port, and outlet port of the plug are all formedtogether as a single, first unitary piece, and the barrel wall, theinternal cavity, the external ejection connector port, the elongatedchannel wall and elongated winding mixing channel, and the bottom of themixing channel are all formed together as a single, second unitarypiece, wherein the reconstitution container device consists of only twopieces.

In yet further detailed aspects, the input end of the winding mixingchannel is located at the inner surface of the barrel component and theejection port is centered in the distal end of the barrel componentalong a longitudinal center axis of the barrel component. The plugoutlet port is located adjacent the proximal end of the plug component.

In other detailed aspects, the plug component and the barrel componentengage each other adjacent the proximal end of the plug component, thediluent distribution groove is formed at the location of engagement ofthe plug and barrel components and the plug outlet port is connectedtherewith. Weld material is formed on at least one of the plug componentand barrel component at the location of engagement of the two outboardof the diluent distribution groove, such that the application ofappropriate energy to the weld material will seal the plug and barrelcomponents together and will seal the diluent distribution groove fromleakage.

Additionally, the plug outlet port is located adjacent the distal end ofthe plug component. The diluent distribution groove is formed 360° inthe plug component in connection with the plug outlet port.

In yet other aspects, the cavity of the barrel component includes a plugmounting shelf, the plug includes a mounting shoulder located to engagethe plug mounting shelf, one of the plug mounting shelf and the mountingshoulder are beveled thereby creating the diluent distribution groove.The barrel component comprises a first snap fit device and the plugcomponent comprises a second snap fit device that is configured toengage the first snap fit device such that, when the plug and barrelcomponents are engaged together, the first and second snap fit devicesengage each other and firmly resist disassembly of the plug and barrelcomponents.

In further more detailed aspects, the reconstitution container device isfurther for drying liquid medication, wherein the outer shape of thebarrel component is selected so that before assembly of the plugcomponent with the barrel component, barrel component may be mounted ina support device with the winding mixing channel in an open channelconfiguration with the open portion of the channel facing upward andwith liquid medication residing in the open cavity for the purpose ofundergoing a drying process, and wherein the distal end of the plugcomponent has a flattened shape such that after the liquid medicationhas been dried to a powder and the plug component is engaged with thebarrel component, the flat distal surface pushes the powder fully intothe mixing channel and closes the top of the mixing channel; wherein thereconstitution container device is useful for drying liquid medication,storing dried medication, and reconstituting dried medication.

In another more detailed aspect, the winding mixing channel is formed asan integral part of the plug component such that the plug component andthe winding mixing channel are a single piece, and wherein the barrelcomponent comprises a proximal closure surface that, when assembled withthe plug component, forms the closing top of the winding mixing channel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 presents a graph of medication concentration (ordinate) percumulative injection volume (abscissa) as is provided by prior artreconstitution devices, in this case for protein content in mg;

FIG. 2 presents a graph of a gradient delivery of “product” ormedication in which the concentration (mg/ml) quickly rises to a peakand then tapers during the remainder of the injection volume to nearzero concentration at 1 ml of cumulative injection volume;

FIG. 3 provides a perspective view of an assembled compactreconstitution container in accordance with aspects of the inventionformed in this case of a plug at the proximal end having a diluent portand a barrel at the distal end having an ejection port with a Luerconnector at each end, the container having dried medication in powderor similar form within for reconstitution;

FIG. 4 is a sectioned slightly perspective view of the container of FIG.3 showing more detail of the plug and barrel, and particularly showing across-sectional view of an elongated winding mixing channel in itsclosed configuration within which dried medication is stored forreconstitution;

FIG. 5 illustrates an elevation perspective view of the device of FIG. 3similar to that of FIG. 4 showing further details with FIG. 5A showingan embodiment of the plug component in which it is generally hollow;

FIG. 6 presents a top view of an elongated channel wall winding arounditself to form a winding mixing channel, in this case in the form of aspiral, that provides an indirect path from a longitudinal diluent flowgroove formed into the inner wall of the barrel component to theejection connector port, the winding mixing channel containing driedmedication that is rapidly reconstituted on contact with diluent thatmust necessarily flow through the mixing channel to reach the ejectionport, and FIG. 6A showing the longitudinal diluent groove in the barrelcomponent connecting with the input end of the winding mixing channel;

FIG. 7 is an exploded view of an application of the compact medicationcontainer of FIG. 3 in which a diluent syringe is used to force diluentinto the powdered medication contained in the medication container forreconstitution, and a sharpened cannula positioned at the ejection portof the device for intravenous or other delivery to a patient, both thediluent port and the ejection port having Luer connectors for bluntconnection with other devices;

FIGS. 8A and 8B illustrate one embodiment of an approach of bonding theplug to the barrel of FIG. 3;

FIGS. 8C and 8D illustrate another embodiment of an approach of bondingthe plug to the barrel of FIG. 3 but adding in this embodiment a weldshield internal to the bonding area to repel any particles that may beproduced in the welding activity;

FIG. 9 is a group of drawings showing features of the inclusion of arubber sealing ring. In particular, FIG. 9 is a perspective explodedview of the device of FIG. 3 also including protective storage caps foreach of the diluent port and the ejection port, the figure also showinga portion of the lateral diluent flow pathway through the plug, and asealing ring installed on the plug component. FIGS. 9A, 9B, and 9Cprovide further detail of the sealing ring;

FIG. 10 illustrates a slight perspective view of an alternative plugcomponent for the device of FIG. 3 in which the lateral diluent flowpath through the plug is lowered towards the distal end of the plug, anda relieved portion of the plug is provided 360° around the plugincluding the external flow port of the lateral pathway through theplug;

FIG. 11 is a cross sectional view of the plug of FIG. 10 assembled withthe barrel but in the embodiment, the plug does not include the relievedportion;

FIG. 12 shows an alternate embodiment of a plug component in an explodedview in which the lateral flow path has been moved distally and thediameter of the distal end of the plug has been reduced to engage with acorrelating reduced inner diameter of the barrel;

FIG. 13 is an assembled view of the components shown in FIG. 12 showinga flow circulation path about the periphery of the plug at the lateralflow path external port;

FIG. 14 illustrates a perspective view of an alternative embodiment of abarrel component of the device of FIG. 3 in which the winding mixingchannel is not formed;

FIG. 15 is a cross-sectional side view of the alternate barrelembodiment of FIG. 14;

FIG. 16 is a perspective view of an alternative embodiment of a plugcomponent in which a winding mixing channel is shown in its openconfiguration, which in this case, is a spiral mixing channel;

FIG. 17 illustrates an exploded perspective view of the embodiment ofFIGS. 14-16 showing more clearly the winding mixing channel, and showingprotective caps on both Luer connectors of the device;

FIG. 18 presents a perspective cross-sectional view of a plug portionhaving a filter disposed in the ejection port of the barrel forfiltering the reconstituted solution exiting the device;

FIG. 19 shows an alternate embodiment in which the plug and barrelcomponents snap fit together with a seal between them, whereby weldingthe plug and barrel together is not necessary;

FIG. 20 is an enlargement of a snap fit mechanism as one embodiment usedherein;

FIG. 21 is a perspective exploded view of a two-piece container deviceof FIG. 19 showing further detail;

FIG. 22 is an enlargement of the snap fit system of FIG. 19 showingfurther detail;

FIG. 23 is an exploded view showing yet another embodiment having a plugcomponent comprising inner and outer portions with a snap fit mechanism;

FIG. 24 is a view of the container of FIG. 23 in which the plugcomponent has been assembled; and

FIG. 25 is an enlarged view of a diluent distribution arrangement forthe container embodiment shown in FIG. 23.

DETAILED DESCRIPTION

Turning now to the drawings in further detail, in which like referencesnumerals indicate corresponding or identical features among the figures,there is shown in FIGS. 3 and 4 a compact reconstitution containerdevice 40 also usable for lyophilization. The reconstitution containerdevice comprises two operating components: a plug component 42 and abarrel component 44. The plug component comprises a diluent connectorport 46 which, in this case, is a standard female Luer connector. Thetab 48 shown in FIG. 3 located on the outside of the connector 46 isusable to engage a locking collar 50 of a male Luer connector 52 (seeFIG. 7) to keep the two firmly engaged. The locking collar and male Luerconnector are all standard connector items in the health care industry.

Both FIGS. 3 and 4 are views of assembled container devices inaccordance with aspects of the invention with FIG. 4 being in crosssection. FIG. 5 is an exploded, partial cross-section view of the samecontainer device as in FIGS. 3 and 4. Continuing now with a discussionof the plug component 42 and referring to all of FIGS. 3 through 5, theplug diluent connector port 46 continues into the plug body and aninterconnecting lateral diluent channel 54 provides fluid communicationout of the plug terminating in a plug outlet port 56. As points ofreference, the plug component 42 has a proximal end 43 and a sideportion 45 through which the lateral internal diluent flow path 54opens. The plug component 42 also includes a distal end 59 having a flatsurface 60 in this embodiment that will be used to form the top wall ofthe mixing channel 70 and configure the internal winding mixing channel70 to a closed configuration, as is discussed below.

A second part of the compact reconstitution container 40 is the barrelcomponent 44. The proximal end of the barrel component 44 has a cavity62 for receiving the distal portion 64 of the plug component. The mixingchannel 70 is also located in the cavity, in this embodiment. The distalportion of the barrel 44 includes a flat surface 66 that provides thebottom wall for the mixing channel 70. Referring to FIG. 6, a topsimplified view of the mixing channel 70 is shown and it will be notedthat in this embodiment, it takes the form of a spiral. It can be seenthat an elongated channel wall 69 having a winding shape is wound arounditself to form the elongated mixing channel 70. The views of FIGS. 4 and5 include many more revolutions of the elongated channel wall 69,although the precise number of revolutions, and therefore the overalllength of the mixing channel 70, can vary.

Although shown as a spiral in FIG. 6, the winding mixing channel 70 canhave other shapes that result in an indirect path from the periphery 68of the cavity 62 of the barrel 44 to the ejection port connector 80.Also shown in FIG. 6 is dried medication 72, shown as specks or dots.The dried medication will normally fill the interior of the mixingchannel 70 as a “cake” of powder, referred to herein also as just“powder.” As diluent is forced into the barrel 44 from the diluentconnector port 46, it will necessarily be forced to flow through themedication 72 in the mixing channel, thereby reconstituting themedication, on its way out of the reconstitution container 40 throughthe ejection connector port 80.

Referring further to FIG. 6, the winding mixing channel 70 is in theopen configuration because the plug component 42 is not sealing thebarrel component 44 and the flat distal surface 60 of the distal end 59of the plug component is not forming the top wall of the mixing channel.In this configuration, or one similar to it, liquid medication residingin the cavity 62 of the barrel can by lyophilized to convert it to driedform, in which case it will be contained within the cavity and inparticular, the mixing channel 70. After lyophilization, the plugcomponent 42 is pressed firmly within the barrel component as shown inFIGS. 4 and 5 to press the powder into the mixing channel and alsochanging the mixing channel to a closed configuration. In this closedconfiguration, diluent forced into the barrel component must traversethe entire mixing channel before traveling out through the ejection port80. There will also be space in the mixing channel between the powderand the top wall 60. As diluent is forced into the mixing channel, itwill traverse the space and at the same time be in contact with thepowder therefore reconstituting the powder and eventually flowing outthrough the ejection connector 80 with a concentration gradient (seeFIG. 2, numeral 36).

Continuing with FIG. 6, a longitudinal diluent flow groove 90 has beenformed into the inner surface 89 of the barrel wall 44. In this case,there exists only one diluent flow channel however more may be formed.It will be noted from the figures that the spiral mixing channel has afixed input end 91 positioned at the cavity 62 inner wall 89. It alsohas a fixed output end 93 at the ejection connector port 80. Onceassembled with the plug, the distal end of 60 forms the top of themixing channel leaving only two access points to the mixing channel, theinput end 91 and the output end 93. Thus diluent must be directed to theinput end so that reconstitution can occur. For this reason, thelongitudinal flow groove 90 has been formed in the barrel inner wall 89.It feeds directly into the input end 91 of the mixing channel 70.However, the longitudinal diluent flow groove 90 is also fixed inposition. It is desirable that the plug be designed so that duringmanufacturing, it can be inserted into the cavity 62 of the barrelcomponent 44 without regard to its rotational orientation. This wouldresult in much less expense in manufacturing.

So that rotational alignment of the plug component 42 with the barrelcomponent 44 is unimportant, a continuous diluent distribution groove 94is used. This groove is formed in at least one of the plug component 42and the barrel component 44 and is positioned to connect with the plugoutlet port 56. The diluent distribution groove 94 is formed in whichdiluent leaving the plug outlet port 56 flows around the periphery ofthe plug component 42 until it encounters the longitudinal diluent flowgroove 90 whereupon it flows through the longitudinal groove in thebarrel to the input end 91 of the winding mixing channel 70 forreconstitution of the medication 72. Because diluent introduced to thediluent input connector 46 is under pressure, it will be forced throughall pathways; i.e., the internal diluent flow path, the plug outletport, the distribution groove, the longitudinal groove, the mixingchannel, and the ejection port.

In the embodiment shown in FIGS. 4 and 5, the diluent distributiongroove 94 is formed with a bevel 94 of the proximal end of the barrelcomponent 44. In particular, the bevel 94 is a cut that removes theinside edge of the proximal end of the barrel component. In thisembodiment, it is formed completely around (360°) the proximal end ofthe barrel component. In addition to providing the distribution groovefor the diluent, this bevel further provides a manufacturing advantageas its taper or “bevel” tends to guide the plug component into correctlongitudinal alignment with the barrel component and therefore affordsgreater ease for assembling the two to become the container device 40.The angle of the bevel in one embodiment is about 45° to about 85°. Incertain embodiments, the bevel may be about 50° to about 65° and incertain embodiments the bevel angle may be about 60°.

Turning briefly now to the ejection port 80, it also includes a Luerconnector, in this case, a male Luer connector with a surroundinglocking cuff 82. A sharpened cannula having a female Luer connector maybe attached to ejection port connector so that the reconstituteddelivery solution flowing out the ejection port may be delivered to apatient through piercing the patient's skin. Other devices may be usedfor delivery of the delivery solution flowing out the ejection port 80.

It is to be noted that the diluent flow path 54 through the plugcomponent 42 need not be precisely lateral and may in fact take otherangles. Similarly, the diluent flow channel 90 need not be preciselylongitudinal but may take other angles.

FIG. 7 presents an application of the compact reconstitution containerdevice 40 of FIGS. 3, 4, and 5. A diluent syringe 100 is shown whichwill be attached to the diluent port 46 of the container device 40. Onceattached, the plunger 102 is pressed into the barrel of the diluentsyringe to expel diluent into the container device 40 under pressureultimately forcing that diluent into the mixing channel 70 toreconstitute the powder contained therein and leave the ejection port 80of the container device as a mixed solution with a concentrationgradient. A sharpened cannula 110 is positioned for attachment to themale Luer connector at the distal end of the container device 40 and maybe used to deliver the solution output by the container device into avein or other injection site of a patient. As mentioned above, otherdelivery devices may be used with the ejection port 80.

Referring now to FIG. 8, which is a group of four figures denoted by A,B, C, and D, FIGS. 8A and 8B show a technique for permanently bondingthe plug component 42 to the barrel component 44. In this case,ultrasonic welding, or similar methods such as laser welding, is used tocreate a firm bond between the two components and provide a water tightdiluent distribution groove or channel 94. Weld material 120 is providedas part of the barrel component 44 in this embodiment, although it maybe provided as part of the plug component 42 or both. In other cases, itmay be desirable to have a barrier between the welding point and thediluent flow channel. Such an arrangement is shown in FIGS. 8C and 8D.In the embodiment of FIGS. 8A and 8B, the barrier 122 is provided by thebarrel component 44 and is located inward from the weld point. Anyparticles resulting from the welding action are trapped between thebarrier 122 and the weld 120.

FIG. 9 presents an exploded view of a reconstitution container device 40in accordance with aspects of the invention including two additionalsealing caps for storage and shipment of the container device. Inparticular, the diluent port includes a watertight cap 120 that sealsand protects the diluent port during storage and shipment. The ejectionport likewise has a watertight protective cap 122 for sealing andprotection. These caps may be formed to slide onto the ports, or mayhave twist mountings (threads), or other, and may include sealingmaterial within. In one embodiment, they would be installed prior to thelyophilization process. Since that process is typically done in anatmosphere of nitrogen, the caps will provide important protection tothe container device 40 after it is assembled and bonded together andsealed in a foil-lined pouch.

Additionally FIGS. 9, 9A, 9B, and 9C show the use of a rubber sealingring 124 between the barrel component 44 and the plug component 42 forthe purpose of providing a barrier to the diluent flow channel againstany weld particles that may be formed during the bonding of thecomponents together and to form a watertight seal. FIGS. 9A and 9B showthe sealing ring 124 and the recess 123 formed in the proximal end 43 ofthe plug component 42 to receive the ring 124. Upon insertion of theplug into the barrel and welding the two together, the rubber ring willbe pressed into the recess 123 and also into tight contact with both theplug component and the barrel component providing a watertight seal andalso providing a complete barrier to the weld yet leaving the diluentflow channel open. FIG. 9C shows the seal compressed into operation forsealing.

FIGS. 10, 11, 12, and 13 present alternate embodiments of the plugcomponent. Referring to FIG. 10, the plug component 140 has the internallateral flow path (not shown) with the diluent plug outlet port 142located adjacent the distal end 60 of the plug component. Also in thisembodiment, the diluent distribution groove 144 is formed in the plugcomponent itself as opposed to being formed in the barrel in FIGS. 4 and5. The distribution groove 144 is connected with the plug outlet port142 as in other embodiments. The effect will be the same as in the priorembodiment in that the diluent distribution groove will connect with thelongitudinal diluent groove 90 (see FIG. 6) regardless of the rotationalorientation of the plug component when inserted into the barrelcomponent.

FIG. 11 presents an embodiment similar to FIG. 10 wherein the plugoutlet port 158 is adjacent the distal end of the plug component. Inthis case, a longitudinal groove 159 may be formed in the plug componentin a proximal direction leading from the plug outlet port 158 to connectwith the diluent distribution groove 94.

In FIGS. 12 and 13, the difference in shapes between the distal end 60of the plug component and a plug mounting shelf 161 in the barrelcomponent the barrel component results in a diluent distribution channel152 located adjacent the distal end 60 of the plug component. Inparticular, FIGS. 12 and 13 have a configuration similar to FIG. 11regarding the location of the internal lateral flow path 150 through theplug component 154, but in this embodiment, the diluent distributionchannel 152 is caused by the difference in shapes between the plugcomponent 154 and the barrel component 156 at the diluent outlet port158. In this embodiment, the barrel component includes the plug mountingshelf 161 that is squared. However, the plug component has a mountingshoulder 163 that is beveled, and when engaging the barrel, a space isleft that operates as the diluent distribution groove 152. Otherconfigurations and shapes are possible for creating the diluentdistribution groove between the plug component and the barrel component.

FIGS. 14 through 17 present a different embodiment wherein the mixingchannel 160 is formed as an integral part of the plug component 162. Asshown in FIGS. 14 and 15, the barrel 166 has an empty cavity 164 havinga size large enough to receive the winding mixing channel 160 that isformed as an integral part of the plug component 162 (see FIG. 16).Turning also to FIG. 16, the plug component 162 has the same diluentconnector port 168, lateral diluent channel 170, but has thelongitudinal diluent flow groove 172 formed in the outside surface 174of the plug that leads directly to the input end 173 of the spiralmixing channel 160. Once again, the orientation of the plug component162 when inserted into the barrel component 166 is unimportant in thatno alignment of the two in relation to each other is necessary. FIG. 17shows protective sealing caps 174 and 176 on each of the two ports ofthe container device 178.

FIG. 18 presents a view of the reconstitution container device 40 ofFIG. 3 with a filter 180 installed in the ejection connector port 80.

FIG. 19 illustrates an alternative embodiment of a compactreconstitution container device 200 for lyophilizing, storing, andreconstituting medication still having two pieces. However, the shape ofthe pieces varies from previous figures in that the plug component 202has a frusto-conical shape with the barrel component 204 and its cavity206 having a complementary shape for receiving the plug component. Allother features remain similar to FIG. 10 except for the addition of asnap fit system 205. With this system 205, no welding is necessary topermanently connect the plug component 202 to the barrel component 204.In particular, the inner surface 210 of the barrel component includes asnap latch 212 that protrudes into the cavity 206. In this case it isplaced near the proximal end 214 of the barrel component. Formed intothe plug component 202 is a complementary snap fit groove/latch 220 forreceiving the snap latch 212 of the barrel component and permanentlyconnecting the two together. FIG. 20 provides an enlarged and somewhatexaggerated view of the operation of one embodiment of such a snap-fitsystem. Other types of snap-fit systems may be used.

FIG. 21 shows further detail of the embodiment of FIG. 19 and provides aperspective view thereof for further clarity. Referring to both FIGS. 19and 21, the plug component 202 includes a lateral diluent path 222 thatterminates in a plug outlet port 224, as in the other embodiments.Formed into the plug component, as in FIG. 10, is the diluentdistribution groove 228. The barrel inner wall surface 210 has formed init the longitudinal diluent groove 230 for receiving the diluent fromthe diluent distribution groove 228 of the plug component and conductingthe diluent to the input end of the mixing channel 232 (FIG. 19). FIG.22 provides an embodiment in which the longitudinal diluent groove isalso cut through the snap fit latch 212 of the barrel component.

FIG. 23 illustrates another alternate embodiment in which no welding isnecessary to permanently connect the plug component 191 to the barrelcomponent 192. In this embodiment, the plug component 191 includes anouter plug portion 197 and an inner plug portion 193. A rubber ring 194will be located between a lip 198 formed at the distal end 199 of theinner plug portion 193 and the distal end 189 of the outer plug portion.As shown in FIG. 24, the rubber ring 194 is compressed between the innerand outer plug portions to complete sealing of the plug assembly 191. Asnap latch mechanism 188 locks the plug assembly to the barrel component192 once it is completely inserted to the barrel component. The barrelcomponent contains a threshold 195 b that can be a full circle or only afew bumps and will serve to catch the incoming plug assembly 191 for thesnap latch mechanism as the bump 195 a in the plug assembly 191 passesthrough it.

As shown in FIG. 25, the water flow is oriented by cutting a waterchannel 196 in the lip 198 of the inner plug 193 so that the water cancirculate 360° right below the rubber ring before finding thelongitudinal diluent groove 188 to the beginning of the mixing channel90.

As is clearly shown in the embodiment of FIGS. 3, 4, 5 and others, theentire compact reconstitution device 40 can be formed of only twopieces, the plug component and the barrel component. This results in amuch less expensive container device than previously available andprovides not only storage but is useful from the beginning the of theprocess where liquid medication is dried through reconstitution anddelivery. Additionally, a gradient concentration delivery is provided.Manufacturing costs are greatly reduced and a wide range of medicationsare compatible with the reconstitution device 40.

Keeping air space to a limited level is also a goal of the design. Thetotal air space, also referred to herein as minimum fluid headspace,refers to the open space in the container device 40 beginning at the tipof the diluent syringe 100 (see FIG. 7) to the proximal end of thelongitudinal diluent flow channel 90 (see FIG. 6), which is where thediluent channel 90 terminates at the mixing channel 70. A desirableminimum fluid head space is about 0.001 mL to about 2 mL or about 0.001mL, about 0.01 mL, about 0.1 mL, or about 0.5 mL. A desirable ratio offill volume to air space to is about 2:1 or about 3:1 or about 4:1. Forinstance, a reconstitution container device having a fill volume ofabout 0.2 mL and a total air space of about 0.1 mL has a ratio of about2:1. The embodiments shown herein in conformance with principles andaspects of the invention fulfill these needs.

Suitable materials contemplated for use in the manufacturing of thecomponents include, for example, cyclo-olefin copolymer, cyclo-olefinpolymer, polycarbonate, polystyrene, Teflon, and the like. Suchmaterials are well known to those of ordinary skill in the art andreadily available.

The reconstitution container device may vary in size and configurationbut is typically cylindrical in overall shape, and has at one end adiluent connector port and at the other end an ejection connector port.An important, unique design feature of the reconstitution containerdevice is the winding mixing channel. The mixing channel provides aspecified path for the diluent to follow in order to reconstitute thelyophilized product contained in the reconstitution container device.The mixing channel serves to enhance the recovery of the powder due tofluid path within the reconstitution container device. The mixingchannel can be any size or shape so long as a specific path is providedto orient the flow of the fluid. For instance, the mixing channel can bea spiral, a maze, and the like and is integrated into the reconstitutioncontainer device. In some embodiments, the mixing channel is a spiralmixing channel having a plurality of revolutions for the water to travelthrough. For instance, a spiral mixing channel can have about 2, 3, 4,5, 10, or 20 revolutions.

At the ejection connector port end, the product container may bespecifically designed to allow attachment via friction fit to either aluer-lock or luer-slip standard needle, comprise a staked needle (with aneedle shield); comprise a nozzle spray tip for nasal delivery; orcomprise a blunt tip for oral or ocular applications. In eachconfiguration, the ejection port end of the product container will havea detachable base which serves to hold and stabilize the productcontainer during filling and during the lyophilization process. Inaddition, the detachable base serves as a needle shield when theejection port end of the product container comprises a staked needle.

The plug component 42 may vary in size and configuration and is capableof engaging with the barrel component 44 with a snug fit to form thereconstitution container device having varying manufacturing and/or enduser functionality. Alternatively, the plug component may comprise oneor more fluid transfer channels which allows for diluent from theattached syringe to flow through the plug component and encounter thelyophilized powder in the mixing channel.

In certain embodiments, the disclosure provides an improved process forthe preparation of a reconstitution container device containing alyophilized powder product. In particular, the barrel component (perhapswith a detachable base) is loaded into an industry standardvial/syringe/cartridge manufacturing filling line in a similar manner asregular vials, syringes, or cartridges. The barrel component is filledwith an optimized liquid formulation containing a pharmaceuticalproduct. The plug component is held above, aligned with and indexed tothe barrel component. The barrel component with indexed plug componentare then placed into the lyophilizer and subjected to a lyophilizationprocess. During lyophilization, vapor escapes from the barrel component.Upon completion of lyophilization, vertical compression of thelyophilizer shelves will press the plug component into the barrelcomponent creating a sealed reconstitution container device andcompressing the dry powder to minimal head space in the mixing channel.The sealed container closure assembly is bonded to provide a tamperresistant assembly which retains the sterility of the active ingredient.

Importantly, in this process, the plug component is pushed down suchthat it presses the pharmaceutical powder into the mixing channel andthere is minimal air space between the mixing channel and the plugcomponent. This design concept reduces the volume of air, reducesresidual drug at the completion of injection, and facilitates the directinjection of the lyophilized powder without the need for a separatereconstitution/mixing/priming step of powder with diluent.

Methods and techniques to be used to bond the sealed assembly are wellknown to those of ordinary skill in the art and include, e.g., gluing,welding. The bonding serves to help maintain seal integrity and providea tamper resistant assembly which retains the sterility of the activeingredient. As such, the bonded sealed reconstitution container deviceof the present invention is able to retain the sterility of thepharmaceutical powder product and is storage stable at room temperatureover the shelf life of the product.

It is understood that the reconstitution container device may vary insize and is readily adaptable to and functional with any standard typepre-filled syringe and standard type needles. Such syringes and needlesare well known to those of ordinary skill in the art and readilyavailable. Generally, the container physical dimensions should be about10 mm×10 mm×50 mm to about 50 mm×50 mm×200 mm, in some embodiments, thephysical dimension are about 25 mm×25 mm×150 mm. The reconstitutioncontainer device should have adequate dimension for a fill volume ofabout 0.01 mL to about 20 mL. In some embodiments, the container hasadequate dimension for a fill volume of about 0.01 mL, 0.1 mL, 0.2 mL,0.3 mL, 0.5 mL, 1.0 mL, 1.5 mL, 2.0 mL, 5 mL, 10 mL, 15 mL, or about 20mL of liquid pharmaceutical product to be lyophilized.

In an improved method for the administration of a lyophilizedpharmaceutical product using the compact container in accordance with anembodiment of the disclosure, the sealing cap at the diluent port isremoved thus exposing the inlet port. The diluent syringe may be mountedto the inlet port by means of a Luer collar engaging the Luer tab ortabs formed as part of the female Luer connector at the proximal end ofthe container. The sealing cap at the ejection port is removed and theappropriate device attached to the Luer connector at that position. Theappropriate device may be a sharpened cannula for direct injection ofthe reconstituted medication of the container. Where this is the case,the sharpened cannula is forced to pierce the skin of the patient at anappropriate injection site for medication delivery.

Simultaneous reconstitution and delivery is begun by forcing the diluentsyringe plunger into the barrel whereupon the diluent in the syringewill be forced into the compact medication container, through the plug,and into the winding mixing channel. Upon contact of the diluent withthe dried medication in the mixing channel, rapid reconstitution of thedried medication into a liquid begins and the reconstituted medicationflows out the ejection port, through the sharpened cannula, and into thepatient. Because there is no separate mixing step, the reconstituteddelivered solution will have a higher concentration initially and theconcentration of medication to diluent in the delivery solution willtaper lower and lower. This is therefore a delivery solution having aconcentration gradient over the time of the delivery from higherconcentration to lower concentration.

As an alternative to the above, the compact reconstitution container mayhave a staked needle at the ejection port end which is exposed byremoving a protective cap. In another embodiment, the compactreconstitution container may comprise a nozzle spray tip at the ejectionport which is exposed by removal of a protective cap. Importantly, innone of the configurations described above is a separatereconstitution/mixing/priming step performed, thereby providing for amore convenient delivery of medication for the patient.

Importantly, the improved delivery methods disclosed herein provide“gradient delivery” of the injectable pharmaceutical product. Forexample, because immediate reconstitution of the powdered drug uponcontact with the diluent is achieved, the product is injected into thepatient in a manner wherein more highly concentrated product is injectedinitially. It is the improved process and reconstitution containerdevice design concept described herein that facilitates the directadministration of the powdered active ingredient, without the need for aseparate reconstitution/mixing step. Accordingly, the lyophilizedformulations, lyophilization processes and reconstitution containerdevice design concepts described herein can be applied to existingdelivery devices, such as, for example, pen systems, autoinjectorsystems, needle-free injector systems, dual-chambered injectioncartridges and/or pre-filled syringe systems, to provide for improvedmethods of administration of powdered drugs which provide for gradientdelivery and which are more user friendly for the patient and/or enduser.

A study was conducted to demonstrate the gradient delivery injectionprofile associated with the administration of a powdered drug using theformulations, lyophilization processes and container closure assemblydesign of the present invention.

The study was performed utilizing a model protein drug substance,Recombinant Human Parathyroid Hormone (PTH) with standard excipients,mannitol and phosphate. The study was performed by using a sealed LyoTipdevice with a 0.2 mL mixing channel volume prepared using the process ofthe present invention and containing 10 mg of PTH powder which was driedin a typical lyophilization process. A syringe containing 1 ml ofdiluent (water) was attached to the plunger assembly of the containerclosure assembly and the detachable base at the neck end of thecontainer closure assembly was removed. Force was applied to the syringeplunger such that the water flowed through the assembly, reconstitutedthe powder, and the resultant solution exited the ejection port of theassembly. The concentration of PTH in each drop of solution was measuredwith an ultraviolet spectrometer. The data collected and shown in FIG. 2characterize the general profile of the gradient delivery associatedwith the administration of a powdered drug using the formulations,lyophilization processes and container closure assembly design of thepresent invention. As depicted in FIG. 2, the concentration of the dosedelivered over the injection volume for a gradient delivery was nonconstant with the bulk of the active pharmaceutical ingredient beingdelivered during the initial portion of the injection.

This unique gradient delivery of the injectable pharmaceutical powderproduct may be advantageous to the patient in certain therapeuticsettings. To date, none of the known prior art delivery techniques anddevices used for delivery of powdered drugs have such a profile, as allrequire a reconstitution and/or mixing step of the powdered drug with adiluent prior to injection, and therefore, have an injection profilesimilar to that depicted in FIG. 2. Although PTH was used in thisexample, those skilled in the art will understand that any activepharmaceutical products, excipients and/or other ingredients can be usedin accordance with the container closure assemblies and methodsdisclosed herein to achieve a gradient delivery injection profile.

Contemplated for use in the container closure assemblies of thedisclosure are storage stable powder formulations of pharmaceuticalproducts. Importantly, the powder formulations are optimized to producepowders which provide for “rapid” dissolution of the lyophilized powder,i.e., the powders are readily and immediately dissolved upon contactwith a liquid diluent. The lyophilized powders comprise an activeingredient, e.g., protein, and a stabilizer. Stabilizers are added tothe lyophilized formulation to enhance the stability of activeingredient. Stabilizers such as, e.g., surfactants, sugars, polymers,antioxidants, amino acids, salts, can be added to stabilize activeingredient during freezing process; and additives that can replacehydrogen bonds of water during dehydration process, e.g., sucrose,trehalose, lactose, or other sugars, can be added to stabilizepharmaceuticals by maintaining their native structure.

In order to maintain large surface area, the powder formulations mayfurther comprise bulking agents that can form crystalline matrices(e.g., mannitol, glycine, polyethylene glycol, and the like).Alternatively, other glassy bulking agents like sugars and polymers,e.g., sucrose, trehalose, lactose, proteins, dextran and itsderivatives, cyclodextran, carboxymethylcellulose, PVA, PVC, starch andits derivatives, can be added to the formulation.

The powder formulations may further comprise surfactants and buffers.Such surfactants include polysorbate 80 (or Tween 80), polysorbate 20(or Tween 20), or pluronics. Such buffers include, e.g., phosphate,histidine, imidazole, citrate, acetate, succinate, glutamate, Tris andglycine can be added to keep desirable pH.

In order to minimize the mass that needs to be dissolved duringinjection, the formulation can be composed mostly by active ingredients.For example, protein or peptide products can be lyophilized with thefinal solid content of 95% of protein or peptide and 5% of stabilizer.

Pharmaceutical products (active ingredients) contemplated for useinclude small molecules, vaccines, live or attenuated cells,oligonucleotides, DNA, peptides, antibodies, and recombinant ornaturally occurring proteins, whether human or animal, useful forprophylactic, therapeutic or diagnostic application. The activeingredient can be natural, synthetic, semi-synthetic or derivativesthereof. In addition, active ingredients can be perceptible. A widerange of active ingredients are contemplated. These include but are notlimited to hormones, cytokines, hematopoietic factors, growth factors,antiobesity factors, trophic factors, anti-inflammatory factors, andenzymes One skilled in the art will readily be able to adapt a desiredactive ingredient to the powdered formulations described herein.

Active ingredients can include but are not limited to insulin, gastrin,prolactin, human growth hormone (HGH), adrenocorticotropic hormone(ACTH), thyroid stimulating hormone (TSH), Thyrotropin alpha,luteinizing hormone (LH), follicle stimulating hormone (FSH), humanparathyroid hormone (PTH), glucagons-like peptide 1 (GLP-1), growthhormone-releasing factor (GRF), human chorionic gonadotropin (HCG),motilin, interferons (alpha, beta, gamma), interleukins (IL-1 to IL-12),interleukin-1 receptor antagonists (IL-1ra), tumor necrosis factor(TNF), tumor necrosis factor-binding protein (TNF-bp), erythropoietin(EPO), granulocyte-colony stimulating factor (G-CSF), stem cell factor(SCF), leptin (OB protein), brain derived neurotrophic factor (BDNF),glial derived neurotrophic factor (GDNF), neurotrophic factor 3 (NT3),fibroblast growth factors (FGF), neurotrophic growth factor (NGF), bonegrowth factors such as osteoprotegerin (OPG), insulin-like growthfactors (IGFs), macrophage colony stimulating factor (M-CSF),granulocyte macrophage colony stimulating factor (GM-CSF), megakaryocytederived growth factor (MGDF), keratinocyte growth factor (KGF),thrombopoietin, platelet-derived growth factor (PGDF), novelerythropoiesis stimulating protein (NESP), bone morphogenetic protein(BMP), superoxide dismutase (SOD), tissue plasminogen activator (TPA),urokinase, Factor VIII, Factor IX, alpha-1 protease inhibitor,Urofollitropin, Menotropins, Lutropin alfa, L-asparaginase,Thrombopoetin receptor antagonist, alteplase, CD2 antagonist,Collagenase, urokinase, Tenecteplase, reteplase, anthrombin III,botulinum toxin, Abatacept, Alglucosidase-alpha, velagucerase alfa,hyaluronidase, Rasburicase, a-galactosidase A, beta-gluco-cerebrosidase,Indursulphase, Larinodase, Galsuphase, C5 antagonist, streptokinase andkallikrein, and various human antibodies and humanized antibodies. Theterm protein, as used herein, includes peptides, polypeptides, consensusmolecules, analogs, derivatives or combinations thereof.

In one embodiment, the lyophilized formulation comprises a model proteindrug substance, recombinant human parathyroid hormone (PTH), withstandard excipients, mannitol and phosphate.

Diluent to be used with the powders contained within the containerclosure assembly can also be customized for the best stability andpatient compliance. Diluents contemplated for use include commerciallyavailable water for injection (WFI), bacteriostatic water for injection(BWFI), or phosphate buffered saline (PBS), etc. Custom developeddiluent can further contain a buffering agent, e.g., acetate, phosphate,histidine, citrate, acetate, succinate, glutamate, and glycine;surfactants; stabilizers; tonicity modifiers like sodium chloride; metalions; local anesthetic agents like lidocaine or benzyl alcohol, andhydrogels for controlled release, etc.

The improved lyophilized formulations, lyophilization processes andclosure assembly design concepts disclosed herein provide patients andend-users with an alternative, less expensive and easier to use devicethan current state-of-the-art delivery systems for lyophilized products.Utilization of the design concept described for container closureassemblies disclosed herein in conjunction with existing deliverydevices provides a valuable and much needed benefit to patientsdependent upon powdered drugs in their therapeutic regimens.

Unless otherwise indicated, all numbers expressing quantities ofingredients, properties such as molecular weight, reaction conditions,and so forth used in the specification and claims are to be understoodas being modified in all instances by the term “about.” Accordingly,unless indicated to the contrary, the numerical parameters set forth inthe specification and attached claims are approximations that may varydepending upon the desired properties sought to be obtained by thepresent invention. At the very least, and not as an attempt to limit theapplication of the doctrine of equivalents to the scope of the claims,each numerical parameter should at least be construed in light of thenumber of reported significant digits and by applying ordinary roundingtechniques. Notwithstanding that the numerical ranges and parameterssetting forth the broad scope of the invention are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin their respective testing measurements.

The terms “a,” “an,” “the,” and similar referents used in the context ofdescribing the invention (especially in the context of the followingclaims) are to be construed to cover both the singular and the plural,unless otherwise indicated herein or clearly contradicted by context.Recitation of ranges of values herein is merely intended to serve as ashorthand method of referring individually to each separate valuefalling within the range. Unless otherwise indicated herein, eachindividual value is incorporated into the specification as if it wereindividually recited herein. All methods described herein can beperformed in any suitable order unless otherwise indicated herein orotherwise clearly contradicted by context. The use of any and allexamples, or exemplary language (e.g., “such as”) provided herein isintended merely to better illuminate the invention and does not pose alimitation on the scope of the invention otherwise claimed. No languagein the specification should be construed as indicating any non-claimedelement essential to the practice of the invention.

Groupings of alternative elements or embodiments of the inventiondisclosed herein are not to be construed as limitations. Each groupmember may be referred to and claimed individually or in any combinationwith other members of the group or other elements found herein. It isanticipated that one or more members of a group may be included in, ordeleted from, a group for reasons of convenience and/or patentability.When any such inclusion or deletion occurs, the specification is deemedto contain the group as modified thus fulfilling the written descriptionof all Markush groups used in the appended claims.

Certain embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention. Ofcourse, variations on these described embodiments will become apparentto those of ordinary skill in the art upon reading the foregoingdescription. The inventor expects skilled artisans to employ suchvariations as appropriate, and the inventors intend for the invention tobe practiced otherwise than specifically described herein. Accordingly,this invention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

It is to be understood that the embodiments of the invention disclosedherein are illustrative of the principles of the present invention.Other modifications that may be employed are within the scope of theinvention. Thus, by way of example, but not of limitation, alternativeconfigurations of the present invention may be utilized in accordancewith the teachings herein. Accordingly, the present invention is notlimited to that precisely as shown and described.

Unless the context clearly requires otherwise, throughout thedescription and the claims, the words “comprise,” “comprising,” and thelike are to be construed in an inclusive sense as opposed to anexclusive or exhaustive sense; that is to say, in a sense of “including,but not limited to.” Words using the singular or plural number alsoinclude the plural or singular number respectively. Additionally, thewords “herein,” “hereunder,” “above,” “below,” and words of similarimport refer to this application as a whole and not to any particularportions of this application. When the word “or” is used in reference toa list of two or more items, that word covers all of the followinginterpretations of the word: any of the items in the list, all of theitems in the list and any combination of the items in the list.

Other embodiments of the invention will be apparent to those skilled inthe art from consideration of the specification and practice of theinvention disclosed herein. It is intended that the specification andexamples be considered as exemplary only, with a true scope and spiritof the invention being indicated by the disclosure above in combinationwith the following paragraphs describing the scope of one or moreembodiments of the following invention.

What is claimed is:
 1. A reconstitution container device forreconstituting a dried medication, the reconstitution container devicecomprising: a plug component having a proximal end, a distal end, and aside portion disposed between the ends, the side portion having aperiphery with an outer surface, the plug component having an externaldiluent connector port, and having an internal diluent flow path fromthe diluent connector port to a plug outlet port located at the sideperiphery; a barrel component engaged with the plug component, thebarrel component having a wall with an inner surface within which isformed an internal cavity with a size selected to contain apredetermined quantity of liquid medication for drying to a powder, thebarrel component also having a distal end with an external ejectionconnector port; an elongated channel wall having a winding shape inwhich it winds around itself to form an elongated winding mixingchannel, the channel wall being located within the barrel component suchthat the channel has a closed bottom and an open top, the channel wallhaving a height and length selected to contain the entire quantity ofpowder completely within the mixing channel while still having openspace remaining in the mixing channel, the mixing channel having aninput end and an output end with the output end connected with theejection port; a continuous diluent distribution groove completelyencircling the plug side portion and formed in at least one of the plugside portion and the inner surface of the barrel, the diluentdistribution groove located so as to be connected with the plug outletport; a diluent interconnecting groove formed longitudinally in thesurface of the inner wall of the barrel component having a lengthselected to connect with the diluent distribution groove and with theinput end of the mixing channel, wherein the mixing channel provides anindirect flow path between the diluent interconnecting channel and theejection port; wherein the top of the elongated channel wall is locatedwithin the barrel component facing the plug component so that when theplug component and the barrel component are assembled together after theliquid medication is dried, the distal end of the plug component pushespowder into the mixing channel, and contacts and closes the top of theelongated mixing channel so that the only access to the powder isprovided by the input and output ends of the mixing channel; and whereinforcing diluent through the diluent port causes it to flow through theplug component, through the distribution groove, through the diluentinterconnecting groove, into the input end of the mixing channel, andthrough the space in the mixing channel in contact with the powder,reconstituting the powder to form a delivery solution having amedication concentration gradient as it flows out the ejection port withinitial flow of reconstituted solution having a higher concentration ofthe medication than later flow of reconstituted medication.
 2. Thereconstitution container device of claim 1 wherein the elongated windingchannel wall is integrally formed as part of the barrel component suchthat the barrel component and the winding mixing channel are a singlepiece, and wherein the plug component comprises a distal closure surfacethat, when assembled with the barrel component, forms the closing top ofthe winding mixing channel.
 3. The reconstitution container device ofclaim 1 wherein the elongated channel wall is wound around itself toform a mixing channel having a spiral shape.
 4. The reconstitutioncontainer device of claim 1 wherein: the plug component having theproximal end, distal end, side portion, external diluent connector port,and outlet port of the plug are all formed together as a single, firstunitary piece; and the barrel wall, the internal cavity, the externalejection connector port, the elongated channel wall and elongatedwinding mixing channel, and the bottom of the mixing channel are allformed together as a single, second unitary piece; wherein thereconstitution container device consists of only two pieces.
 5. Thereconstitution container device of claim 1 wherein the input end of thewinding mixing channel is located at the inner surface of the barrelcomponent and the ejection port is centered in the distal end of thebarrel component along a longitudinal center axis of the barrelcomponent.
 6. The reconstitution container device of claim 1 wherein theplug outlet port is located adjacent the proximal end of the plugcomponent.
 7. The reconstitution container device of claim 6 wherein:the plug component and the barrel component engage each other adjacentthe proximal end of the plug component; the diluent distribution grooveis formed at the location of engagement of the plug and barrelcomponents and the plug outlet port is connected therewith.
 8. Thereconstitution container device of claim 7 wherein weld material isformed on at least one of the plug component and barrel component at thelocation of engagement of the two outboard of the diluent distributiongroove, such that the application of appropriate energy to the weldmaterial will seal the plug and barrel components together and will sealthe diluent distribution groove from leakage.
 9. The reconstitutioncontainer device of claim 1 wherein the plug outlet port is locatedadjacent the distal end of the plug component.
 10. The reconstitutioncontainer device of claim 9 wherein the diluent distribution groove isformed 360° in the plug component in connection with the plug outletport.
 11. The reconstitution container device of claim 9 wherein: thecavity of the barrel component includes a plug mounting shelf; the plugincludes a mounting shoulder located to engage the plug mounting shelf;one of the plug mounting shelf and the mounting shoulder are beveledthereby creating the diluent distribution groove.
 12. The reconstitutioncontainer device of claim 1 wherein the barrel component comprises afirst snap fit device and the plug component comprises a second snap fitdevice that is configured to engage the first snap fit device such that,when the plug and barrel components are engaged together, the first andsecond snap fit devices engage each other and firmly resist disassemblyof the plug and barrel components.
 13. The reconstitution containerdevice of claim 1 further for drying liquid medication: wherein theouter shape of the barrel component is selected so that before assemblyof the plug component with the barrel component, barrel component may bemounted in a support device with the winding mixing channel in an openchannel configuration with the open portion of the channel facing upwardand with liquid medication residing in the open cavity for the purposeof undergoing a drying process; and wherein the distal end of the plugcomponent has a flattened shape such that after the liquid medicationhas been dried to a powder and the plug component is engaged with thebarrel component, the flat distal surface pushes the powder fully intothe mixing channel and closes the top of the mixing channel; wherein thereconstitution container device is useful for drying liquid medication,storing dried medication, and reconstituting dried medication.
 14. Thereconstitution container device of claim 1 wherein the winding mixingchannel is formed as an integral part of the plug component such thatthe plug component and the winding mixing channel are a single piece,and wherein the barrel component comprises a proximal closure surfacethat, when assembled with the plug component, forms the closing top ofthe winding mixing channel.
 15. The reconstitution container device ofclaim 1 wherein: the plug component comprises an inner and outer portionwith a seal disposed between the two; a snap fit portion disposed on aninner wall of the barrel component adjacent its proximal end; and acomplementary snap fit portion disposed on an outer wall of the plugcomponent positioned so as to engage the barrel component snap fitportion to physical lock the plug component to the barrel component in adesired configuration when the two are assembled together.
 16. Areconstitution container device for reconstituting a dried medication,the reconstitution container device comprising: a plug component havinga proximal end, a flattened distal end, and a side portion disposedbetween the ends, the side portion having a periphery with an outersurface, the plug component having an external diluent connector port,and having an internal diluent flow path from the diluent connector portto a plug outlet port located at the side periphery, all of which areformed together as a single unitary piece; a barrel component engagedwith the plug component, the barrel component having a wall with aninner surface within which is formed an internal cavity with a sizeselected to contain a predetermined quantity of liquid medication fordrying to a powder, the barrel component also having a distal end withan external ejection connector port located along a center longitudinalaxis; an elongated channel wall having a winding shape in which it windsaround itself to form an elongated winding mixing channel in a spiralshape, the channel wall being located within the barrel component suchthat the channel has a closed bottom and an open top, the channel wallhaving a height and length selected to contain the entire quantity ofpowder completely within the mixing channel while still having openspace remaining in the mixing channel, the mixing channel having aninput end located at the inner surface of the barrel wall, and an outputend with the output end connected with the ejection port; a continuous360° diluent distribution groove formed in the barrel wall completelyencircling the plug side portion, the diluent distribution grooveconnected with the plug outlet port; a diluent interconnecting grooveformed longitudinally in the surface of the inner wall of the barrelcomponent having a length selected to connect with the diluentdistribution groove and with the input end of the mixing channel,wherein the mixing channel provides an indirect flow path between thediluent interconnecting channel and the ejection port; wherein the topof the elongated channel wall is located within the barrel componentfacing the plug component so that when the plug component and the barrelcomponent are assembled together after the liquid medication is dried,the distal end of the plug component pushes powder into the mixingchannel, and contacts and closes the top of the elongated mixing channelso that the only access to the powder is provided by the input andoutput ends of the mixing channel; and wherein forcing diluent throughthe diluent port causes it to flow through the plug component, throughthe distribution groove, through the diluent interconnecting groove,into the input end of the mixing channel, and through the space in themixing channel in contact with the powder, reconstituting the powder toform a delivery solution having a medication concentration gradient asit flows out the ejection port with initial flow of reconstitutedsolution having a higher concentration of the medication than later flowof reconstituted medication.
 17. The reconstitution container device ofclaim 16 wherein: the plug component having the proximal end, distalend, side portion, external diluent connector port, and outlet port ofthe plug are all formed together as a single, first unitary piece; andthe barrel wall, the internal cavity, the external ejection connectorport, the elongated channel wall and elongated winding mixing channel,and the bottom of the mixing channel are all formed together as asingle, second unitary piece; wherein the reconstitution containerdevice consists of only two pieces.
 18. The reconstitution containerdevice of claim 17 wherein: the plug component and the barrel componentengage each other adjacent the proximal end of the plug component; andthe diluent distribution groove is formed at the location of engagementof the plug and barrel components and the plug outlet port is connectedtherewith.
 19. The reconstitution container device of claim 18 whereinweld material is formed on at least one of the plug component and barrelcomponent at the location of engagement of the two outboard of thediluent distribution groove, such that the application of appropriateenergy to the weld material will seal the plug and barrel componentstogether and will seal the diluent distribution groove from leakage. 20.A reconstitution container device for reconstituting a dried medication,the reconstitution container device comprising: a plug component havinga proximal end, a flattened distal end, and a side portion disposedbetween the ends, the side portion having a periphery with an outersurface, the plug component having an external diluent connector port,and having an internal diluent flow path from the diluent connector portto a plug outlet port located at the side periphery, all of which areformed together as a single unitary piece; a barrel component engagedwith the plug component, the barrel component having a wall with aninner surface within which is formed an internal cavity with a sizeselected to contain a predetermined quantity of liquid medication fordrying to a powder, the barrel component also having a distal end withan external ejection connector port located along a center longitudinalaxis; an elongated channel wall having a winding shape in which it windsaround itself to form an elongated winding mixing channel in a spiralshape, the channel wall being located within the barrel component suchthat the channel has a closed bottom and an open top, the channel wallhaving a height and length selected to contain the entire quantity ofpowder completely within the mixing channel while still having openspace remaining in the mixing channel, the mixing channel having aninput end located at the inner surface of the barrel wall, and an outputend with the output end connected with the ejection port; a continuous360° diluent distribution groove formed in the side wall of the plugcomponent completely encircling the plug side portion, the diluentdistribution groove connected with the plug outlet port; a diluentinterconnecting groove formed longitudinally in the surface of the innerwall of the barrel component having a length selected to connect withthe diluent distribution groove and with the input end of the mixingchannel, wherein the mixing channel provides an indirect flow pathbetween the diluent interconnecting channel and the ejection port;wherein the top of the elongated channel wall is located within thebarrel component facing the plug component so that when the plugcomponent and the barrel component are assembled together after theliquid medication is dried, the distal end of the plug component pushespowder into the mixing channel, and contacts and closes the top of theelongated mixing channel so that the only access to the powder isprovided by the input and output ends of the mixing channel; and whereinforcing diluent through the diluent port causes it to flow through theplug component, through the distribution groove, through the diluentinterconnecting groove, into the input end of the mixing channel, andthrough the space in the mixing channel in contact with the powder,reconstituting the powder to form a delivery solution having amedication concentration gradient as it flows out the ejection port withinitial flow of reconstituted solution having a higher concentration ofthe medication than later flow of reconstituted medication.